Failure Study on Crankshaft and Performance Evaluation of Modern Composite Weightless Crankshaft With Enhanced Load Carrying Capacity

Crankshafts represent one of the most critical components in internal combustion engines, converting reciprocating motion into rotational power while enduring complex cyclic loading conditions. Despite significant advancements in materials and manufacturing, crankshaft failures continue to pose substantial challenges to engine reliability, operational safety, and economic efficiency. This comprehensive study investigates the predominant failure mechanisms in conventional steel crankshafts, including fatigue fracture, torsional vibration-induced damage, bearing wear, and surface degradation. Through systematic analysis of failure cases and operational stress distributions, this research identifies critical stress concentration zones and loading patterns that initiate catastrophic failures.